Laminate forming and applying apparatus and method and product therefrom

ABSTRACT

A continuous structural laminate includes a plurality of continuous generally parallel spaced integrally bonded porous blankets with a continuous polymeric matrix extending through each porous blanket. The polymeric matrices include solidified polymeric mixtures with each mixture including a polymer forming material, a gas foaming agent, a catalyst and a major portion of a particulate reinforcement. The polymeric matrices include compatible polymer forming materials. At least two of the blankets include polymeric matrices with differing particulate reinforcements. The continuous structural laminate is formed and applied with mobile apparatus including a support portion, a raw material supplying portion, a mixing portion, a matrix forming portion and a control portion. The support portion includes at least two base sections with carriages depending from a first base section including a plurality of spaced transverse axle assemblies and wheels mounted on free ends of each axle assembly. A boom section extends from the first base section with transfer mechanism selectively moving a second base section along the boom section. The raw material supplying portion includes a plurality of reservoirs disposed on the first base section. A blanket support also is disposed on the first base section. The mixing portion, matrix forming portion and blanket combining mechanism are disposed closely adjacent to the second base section and movable therewith.

This application is a divisional of application Ser. No. 07/417,501,filed Oct. 5, 1989, now U.S. Pat. No. 4,955,760, which is acontinuation-in-part of application Ser. No. 07/235,205, filed Aug. 23,1988, now U.S. Pat. No. 4,872,784.

The invention relates to a novel mobile laminate forming and applyingapparatus and method and to a new continuous structural laminateproduced therefrom.

In primitive societies, travel from one location to another was alongthe most accessible route through the natural terrain. Continuingtraffic along the same route produced a permanent path that served bothhuman beings and their animals. However, as civilizations developed andvehicles attempted to use such narrow pathways, it was necessary toremove obstacles along the edges to provide a wider path that couldaccommodate the vehicles. Further travel by vehicles compacted the baseand created a rough roadway.

Later as motorized vehicles became more common, traffic on theseprimitive roads increased to an extent that it became necessary toprovide areas of greater width periodically to accommodate the passingof vehicles. Along with the increased traffic, another problem was thecapability of motor vehicles to operate at ever increasing speeds. Tohandle such traffic safely, it was necessary to upgrade road systems bybuilding multi-lane roads and by paving the roads to provide a smoothersurface.

Although highway designs and construction methods have become moresophisticated through the years, there have been no major advances sincethe building of the coast-to-coast freeway systems. Also, improvementsin the durability of our roads have not kept pace with highway designs.As a result, a great deal of highway maintenance is required every year.

While we are more aware of highway maintenance due to the detours andother delays we encounter as we travel and the increases in our taxesfor this maintenance, many other surfaces that we encounter regularlyperform just as poorly. For example, athletic fields covered withartificial turf instead of grass are reported to increase the frequencyand severity of player injuries. Many football players say that fallingon artificial turf is like falling on concrete.

In other athletic activities such as high jumping and pole vaulting, itnow is common to use monstrous inflated bags in the landing area. Suchbags are required because natural field surfaces do not providesufficient cushioning to prevent injuries.

From the above discussion, it is apparent that surfaces being usedcurrently and in the past do not meet fully our present and futurerequirements. Thus, there is a need for new surfaces that fulfill ourdesired characteristics.

The present invention provides a novel mobile laminate forming andapplying apparatus, method and product which overcome the deficienciesof previous expedients. The invention not only overcomes theshortcomings, but also provides features and advantages not found inprevious technology. The mobile laminate forming and applying apparatusand method of the invention produce a uniform high quality structurallaminate continuously and quickly with a minimum of base preparation.The laminate is formed and placed with little hand labor. With theapparatus and method of the invention, the structure and composition ofthe laminate can be changed along its length as desired automatically toprovide special surface performance characteristics such as greaterdurability, cushioning, load bearing, water removal, gripping and thelike.

The mobile laminate forming and applying apparatus of the presentinvention is simple in design and can be produced relativelyinexpensively. Commercially available materials and components can beutilized in the manufacture of the apparatus. Conventional metal workingfabricating procedures can be employed by semi-skilled labor in themanufacture of the apparatus.

Also, semi-skilled workmen can operate the apparatus of the inventionefficiently after a minimum of instruction. The apparatus is durable inconstruction and has a long useful life with little maintenance.

The apparatus and method of the invention can be modified to form avariety of different laminates. Variations in physical dimensions,composition, surface appearance and other performance characteristicscan be achieved quickly. Even with such variations, uniform quality ofconfiguration and composition are maintained without difficulty.

These and other benefits and advantages of the novel mobile laminateforming and applying apparatus, method and product of the presentinvention will be apparent from the following description and theaccompanying drawings in which:

FIG. 1 is a side view of one form of mobile continuous structurallaminate forming and applying apparatus of the invention;

FIG. 2 is a top view partially in section of the laminate forming andapplying apparatus shown in FIG. 1;

FIG. 3 is an enlarged fragmentary side view in section of the mixing andmatrix forming portions of the laminate forming and applying apparatusshown in FIGS. 1 and 2;

FIG. 4 is a schematic illustration of one form of control portion of thelaminate forming and applying apparatus of the invention; and

FIG. 5 is an enlarged fragmentary cross-sectional view of one form ofstructural laminate of the invention.

As shown in the drawings, one form of mobile continuous structurallaminate forming and applying apparatus 11 of the present inventionincludes a support portion 12, a raw material supplying portion 13, amixing portion 14, a matrix forming portion 15 and a control portion 16.

The support portion 12 of the mobile laminate forming and applyingapparatus 11 of the invention includes at least two base sections 20 and21. Carriage means 22 depending from base section 20 includes aplurality of spaced transverse axle assemblies 23 and 24 with wheels 25and 26 mounted on free ends 27 and 28 of each axle assembly.

A boom section 31 extends from the first base section 20, advantageouslysubstantially perpendicular to the axle assemblies 23 and 24. Transfermeans 32 is associated with boom section 31 and disposed therealong. Thetransfer means 32 preferably includes drive means 33 and track means 34which selectively moves second base section 21 along the boom section.

The raw material supplying portion 13 of the laminate forming andapplying apparatus 11 includes a plurality of reservoirs 36, 37, 38, 39,40 and 41 as required. These reservoirs may include resin formingmaterials, fillers, reinforcements, colors, catalysts, foam formingmaterials, other additives, inert mixtures thereof and the like.Reservoirs 40 and 41 are connected with reservoir 36 for premixing ofinert materials therein prior to transfer to the mixing portion 14.

Reservoirs 36-39 of the raw material supplying portion 13 areindependently connected to the mixing portion 14 through conduit means43, 44, 45 and 46. Advantageously, separate bypass return conduit means47 extend from one end of each conduit 43-46 adjacent the mixing portion14 back to the respective reservoir 36-39 as illustrated in FIGS. 2 and4.

Blanket support means 49 also is disposed on the first base section 20.Advantageously, the blanket support means accommodates a significantlength of one or more continuous porous blankets shown as rolls 50, 51and 52 in a dispensing orientation. Suitable porous blankets includewoven, knit, non-woven structures and the like. The blankets, e.g.fabrics, mats, etc. may be formed of continuous or discontinuous fibers,yarns, slit ribbons and the like. If desired, reinforcing members suchas ropes, cables, scrims, etc. that extend longitudinally and/ortransversely of the blanket centerline may be included therein.

The mixing portion 14 of the laminate forming and applying apparatus 11of the invention includes mixing chambers 53 and 54. The chambers aredisposed adjacent the second base section 21 and movable therewith. Aplurality of deflector sections 55 are disposed within the mixingchamber spaced along the length of the chamber. The deflector sectionsadvantageously are movable with respect to the chamber.

The matrix forming portion 15 of the apparatus 11 includes polymericmixture delivery means 56. The delivery means is disposed closelyadjacent to and movable with the mixing portion 14 and the second basesection 21.

The mixture delivery means 56 advantageously includes an elongatedchamber 57 that is disposed substantially parallel to the blanketsupport means 49, that is, substantially perpendicular to the line ofmovement of the blankets through the matrix forming portion.

The matrix forming portion 15 also includes blanket combining means 59.The blanket combining means advantageously includes a compression roller60. Preferably, the combining means includes at least one pair ofcooperating aligned rollers 60 and 61.

The matrix forming portion advantageously includes laminate cuttingmeans 63, laminate end grasping means 64 and cut monitoring means 65 todetect the cut and activate the end grasping means. The matrix formingportion 15 and the mixing portion 14 preferably are disposed on thesecond base section 21.

The control portion 16 of the laminate forming and applying apparatus 11of the present invention includes a plurality of pumps, valves, sensors,monitors and the like. Advantageously, a pump 67, 68, 69 or 70; a valve72, 73, 74 or 75; and a flow monitor 77, 78, 79 or 80 are located alongthe length of each conduit 43-46 respectively that extends between theraw material reservoirs 36-39 and the mixing chambers 53, 54.

The control portion 16 also includes a plurality of drive means. A firstdrive 82 advantageously advances the laminate forming and applyingapparatus along a preselected path for the application of the structurallaminate of the invention thereto. Preferably, a second drive means 83advances the continuous porous blankets through the matrix formingportion 15. As disclosed above, a third drive 33 preferably moves thesecond base section along track 34.

The pumps, valves, drives and other components are controlled byactuating means 85 that is responsive to information from the flowmonitors and other sensors. The actuating means also is responsive toinstructions from programmable memory means 86. The pumps, valves,drives etc. of the control portion preferably include electrical motors.

Advantageously, the control portion includes coordinating means 87,preferably including a process controller 88. The process controllerinitiates changes in the flows of materials and speeds of drives tobring variations therein back to the rates specified in the programpresent in the memory means 86.

This coordination commonly is achieved through the transmission ofinformation such as digital pulses from the monitors and/or sensors atthe control components to the process controller 88. The operatinginformation is compared with the preselected programming parametersstored in the memory. If differences are detected, instructions from thecontroller change the operation of the components to restore the formingoperation to the preselected process specifications.

Novel continuous structural laminates of the present invention may beformed using the mobile apparatus 11 shown in FIGS. 1-3 employing thefollowing steps of the method of the invention. The design of thestructural laminate is established by reference to the condition of thebase surface and the intended use of the laminated surface as well asother pertinent factors. The process parameters for the particularlaminate being formed are programmed into the control portion 16including memory 86 which may be a computer.

A minimum of base preparation is required. With a new surface, formingthe base surface in the desired configuration usually is all that isnecessary. With base surfaces that previously have been used, surfacepreparation may require restoration to the original configuration oranother that is desired. In any case, the base preparation is much lessthan for placing concrete mixes, plastic films, preformed coverings,etc. When the base is ready, buttons 91 on panel 92 are depressed tomove apparatus 11 into position with second base section 21 thereof overthe part of the surface 90 being covered initially.

The depression of the buttons and/or switches also has activated memorymeans 86, actuating means 85 coordinating means 87 and the othercomponents of the control portion. The pumps 67-70, valves 72-75 andflow monitors 77-80 are energized in the preselected sequences of thememory. This causes the raw materials stored in reservoirs 36-39 toadvance along the respective conduits 43-46 toward the mixing chambers53 and 54. For example, to produce a foamed polyurethane resin matrix,reservoir 36 may contain an isocyanate, 37 a polyol, 38 a gas foamingagent and 39 a catalyst. The other reservoirs contain fillers,reinforcements, colors, etc. which are added in various proportions,sizes and types.

The delivery of raw materials to the mixing chambers 53 and 54 will varydepending upon the particular formulation and quantity thereof requiredfor a specific incremental area of the laminate being formed at thatmoment. Although the flows through the conduits into the mixing chamberswill vary, it is important that the raw materials entering the mixingchambers maintain a uniform quality. This can be accomplished byincluding for each conduit 43-46 a bypass 47 that extends from the endof the conduit adjacent the mixing chambers back to the respectivereservoir.

The control portion 16 coordinates the operation of the various systemcomponents so the required polymeric formulation flows from a firstmixture delivery chamber 57 into a first blanket 50 passing thereunder.Simultaneously, a second blanket 51 moves under a second mixturedelivery chamber 58 from which a second polymeric formulation flows intothe blanket passing thereunder. In the same way, other formulations maybe applied to additional blankets (not shown). Thereafter, the blanketsare combined as shown in FIGS. 1 and 3.

The combined blankets then pass between pressure rollers 59 whichcompress the impregnated blankets together and at the same time work thesolidifiable polymeric mixtures into the interstices of the blankets foruniform distribution thereof to achieve a continuous matrix within theblankets. The resulting laminate 95 is immediately laid on the basesurface, the leading end secured in place and the laminate conformedwith the configuration thereof preferably before reaching the peakexotherm of the resin forming reaction taking place. In this state, theresin matrix is adhesive and tightly bonds the laminate to the basesurface.

As the laminate 95 is being laid continuously on the base, second basesection 21 automatically is advanced along the base surface at the samerate. This can be done by advancing the entire apparatus 11. Morepreferably, the apparatus 11 is moved periodically and at each stop asection of the laminate is laid on the surface by moving the second basesection 21 along the boom section to maintain continuously the alignmentof the base section with the base surface. When one laminate length iscompleted, the apparatus is moved back along the surface, stopped againand the laminate forming and applying sequence repeated. In this way,the second base section 21 and the laminate easily can be aligned moreprecisely.

The application of the laminate according to the above method can becompleted quickly with a minimum of base preparation. Also, areas alongthe length of the laminate can be customized automatically to providethe particular surface characteristics required for a specific surfacearea. The laminate is permanently conformed to the base surfaceconfiguration and is firmly anchored thereto.

FIG. 5 illustrates an enlarged fragmentary cross-sectional view of thelaminate 95 shown in FIG. 1. The laminate includes three spaced blankets50, 51 and 52 with continuous resin matrices 96 therethrough. The resinis foamed in place and the laminate has a dense outer skin surface 97with pores 98 increasing in size and number with increasing distancefrom the outer surface. Reinforcements 99 increase in size top tobottom.

Laminates of the present invention provide a novel combination ofperformance characteristics not previously attainable. This novelcombination is achieved through the invention by simultaneously formingindividual customized stratas of the laminate. Each strata includes acontinuous porous blanket with a continuous polymeric matrix therein.The resin forming materials, fillers, reinforcements and othercomponents are individually preselected to bestow particular uniqueproperties to the strata.

The continuous structural laminate of the present invention includes aplurality of continuous generally parallel spaced integrally bondedporous blankets. Advantageously, at least two of the blankets differ inthickness and preferably the blankets increase in thickness from one tothe next through the thickness of the laminate. At least two blanketsadvantageously differ in overall configuration and/or preferably basicingredient configuration. The blankets also may differ in chemicalcomposition. Advantageously, at least one of the blankets includesnatural fibrous material and preferably consists essentially thereof.

A continuous polymeric matrix extends through each porous blanket of thelaminate of the invention. The matrix may be achieved by directapplication of a polymeric mixture to a blanket or by transfer of thepolymeric mixture from an adjoining blanket. The polymeric matricesinclude compatible polymeric materials and at least two blankets includediffering particulate reinforcements.

Advantageously, each polymeric mixture includes a polymer formingmaterial, a gas foaming agent, a catalyst and a particulatereinforcement. The polymeric matrices preferably include substantiallythe same polymers.

The polymeric matrices advantageously include a major portion of aparticulate reinforcement. Preferably, at least two of the polymericmatrices include substantially the same reinforcement in differingparticle form. Advantageously, at least two of the reinforcementsinclude natural mineral particles. The reinforcements preferablyincrease in particle size from one blanket to the next through thethickness of the laminate.

The polymer impregnated blankets are combined while the resins thereinare still plastic to integrally form a laminate. In turn, the laminatewhile still plastic is applied to a base surface and tightly bondsthereto.

The laminates of the invention can replace multilayer operations such asthe paving of roads which ordinarily are constructed by applying a baseof coarse gravel, a layer of smaller gravel, followed by a base pavinglayer which is topped off with a finish paving. Since each layer isindependent of the others, any breakdown or settling of one layer maycause damage to the other layers because each does not possessstructural integrity by itself.

With a road laminate of the present invention, each strata hasstructural integrity of itself while including the same size gravelmaterial. Also, the stratas are combined before the polymer has set soan integral structural laminate is formed in which the impregnatedblankets adhere tightly to one another. Furthermore, the completelaminate is applied in one operation rather than successive operationsover a period of time. This not only saves time but also eliminates thepossibility of environmental conditions damaging the independent layersbefore the succeeding layers are applied thereover.

Not only are the individual stratas custom designed but also one or moreof the individual stratas can be changed along their lengths as desired.In this way, a large surface area can be covered with a durablecontinuous laminate surface in which specific areas thereof provideappropriate surface characteristics for many different activities. Thus,a single surface can include a custom outer running track surface, withspecially cushioned infield areas at the landing pits for high jumping,long jumping and pole vaulting. Also, a central area can provide a harddurable surface for dancing and/or stage activities.

The laminates of the invention are useful for playing fields forbaseball, football, soccer, etc. A complete multistrata laminate whichcan be applied in a single operation may be designed to provide waterdrainage, cushioning, a pleasing surface appearance, outstandingdurability and freedom from strats separation and/or settling. In suchapplications of the laminate of the invention, changes from hard toresilient reinforcement particles may achieve the desired differences incushioning.

The above description and the accompanying drawings show that thepresent invention provides a novel mobile structural laminate formingand applying apparatus, method and product with features and advantagesnot known previously. The base surface requires a minimum of preparationbefore the laminate is applied. The laminate can be placed at depressedtemperatures. The laminate is formed and applied with a minimum ofsupervision and labor.

The configuration and composition of the laminate can be changed alongits length automatically to meet the requirements for particular areas.The laminate is set in the configuration of the base and anchoredthereto.

The apparatus and method permit a large variety of laminates to beproduced. Changes from one laminate structure to another can be madeeasily and quickly.

It will be apparent that various modifications can be made in theparticular structural laminate forming and applying apparatus, methodand product described in detail above and shown in the drawings withinthe scope of the present invention. The size, configuration andarrangement of components, steps and materials can be changed to meetspecific requirements. For example, the number of components andreservoirs can be different. Also, the apparatus may include differentdrive, actuating and other components and mechanisms. These and otherchanges can be made in the apparatus, method and product provided thefuncioning and operation thereof are not adversely affected. Therefore,the scope of the present invention is to be limited only by thefollowing claims.

What is claimed is:
 1. A method of continuously forming a continuousstructural laminate and applying said laminate to a surface includingthe steps of dispensing continuously a first solidifiable liquidpolymeric mixture uniformly to a continuously advancing first porousblanket, dispensing continuously a second solidifiable liquid polymericmixture uniformly to a continuously advancing second porous blanket,dispensing continuously an individually pre-selected solidifiable liquidpolymeric mixture to each remaining continuously moving porous blanket,combining said advancing porous blankets into a single laminate witheach blanket closely adjacent to adjoining blankets, monitoring the rateof advance of each blanket, coordinating said rate of advance with theflow rate of the liquid polymeric mixture thereon, monitoring therelationship of the blankets to one another in the combined laminate,immediately applying the freshly formed laminate to a surfacecontinuously while said laminate is deformable and adhesive,simultaneously conforming said laminate to said surface configurationand setting said laminate in the configuration thereof.
 2. A continuousstructural laminate formed according to the method of claim 1 wherein atleast two of said porous blankets differ in thickness.
 3. A continuousstructural laminate formed according to the method of claim 1 wherein atleast two of said porous blankets differ in construction.
 4. Acontinuous structural laminate formed according to the method of claim 1wherein at least two of said porous blankets differ in chemicalcomposition.
 5. A continuous structural laminate formed according to themethod of claim 1 wherein said blankets increase in thickness from oneto the next through the thickness of said laminate.
 6. A continuousstructural laminate formed according to the method of claim 1 wherein atleast one of said blankets includes natural fibrous material.
 7. Acontinuous structural laminate formed according to the method of claim 1wherein at least one of said blankets consists essentially of naturalfibrous material.
 8. A continuous structural laminate formed accordingto the method of claim 1 wherein said polymeric matrices includesubstantially the same polymers.
 9. A continuous structural laminateformed according to the method of claim 1 wherein at least two of saidpolymeric matrices include different particulate reinforcements.
 10. Acontinuous structural laminate formed according to the method of claim 1wherein at least one of said particulate reinforcements includes naturalmineral particles.
 11. A continuous structural laminate formed accordingto the method of claim 1 wherein said particulate reinforcementsincrease in particle size from one blanket to the next through thethickness of said laminate.
 12. A method of continuously forming andapplying a continuous structural laminate according to claim 1 whereinat least one of said porous blankets is formed of interconnecteddiscontinuous fibers.
 13. A method of continuously forming and applyinga continuous structural laminate according to claim 12 wherein saidporous blanket is a straw blanket rolled into a cylindrical bale.
 14. Amethod of continuously forming and applying a continuous structurallaminate according to claim 1 wherein said solidifiable liquid polymericmixture is a thermosetting resin forming mixture.
 15. A method ofcontinuously forming and applying a continuous structural laminateaccording to claim 1 wherein the flow rates of components delivered to amixing portion are individually monitored.
 16. A method of continuouslyforming and applying a continuous structural laminate according to claim15 wherein said components are mixed by moving them through said mixingchamber along a tortuous path.
 17. A method of continuously forming andapplying a continuous structural laminate according to claim 1 whereinsaid laminate is applied to said surface and conformed thereto beforethe mixture therein reaches its peak exothermic reaction.
 18. A methodof continuously forming and applying a continuous structural laminateaccording to claim 1 including the step of combining said impregnatedblankets with spaced longitudinal strength members.
 19. A continuousstructural laminate set in a preselected configuration formed accordingto the method of claim 1.